Positive electrode active material for nonaqueous electrolyte secondary battery, manufacturing method of same, and nonaqueous electrolyte secondary battery using same

ABSTRACT

A method for manufacturing a positive electrode active material includes: (a) preparing a fired powder of a lithium nickel composite oxide by mixing a nickel compound selected from a nickel hydroxide including nickel, and an element selected from other transition metal elements, elements of the second group and elements of the thirteenth group of the Periodic System, a nickel oxyhydroxide thereof, and a nickel oxide obtained by roasting thereof, and a lithium compound, and firing the mixture at a maximum temperature of 650° C. to 850° C. under oxygen atmosphere; and (b) preparing a lithium nickel composite oxide powder by mixing the fired powder with water to obtain a slurry, washing the fired powder with water at a temperature of 10° C. to 40° C., while controlling an electrical conductivity of a liquid portion of the slurry to 30 mS/cm to 60 mS/cm, then filtering and drying the resultant fired powder.

CROSS-REFERENCE OF RELATED APPLICATIONS

This application is a Divisional of application Ser. No. 14/119,350filed Nov. 21, 2013, which is a 371 of International Application No.PCT/JP2012/063596 filed May 28, 2012, which claims priority of JapanesePatent Application No. 2011-163341 filed Jul. 26, 2011 in Japan, theentire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a positive electrode active materialfor a nonaqueous electrolyte secondary battery, a method for producingthe same, and a nonaqueous electrolyte secondary battery using the same,and more specifically to a positive electrode active material for anonaqueous electrolyte secondary battery that combines a high capacitywith excellent thermal stability and enables a high output, a method forproducing the same, and a nonaqueous electrolyte secondary batteryhaving a high capacity, a high output and high safety that uses thepositive electrode active material.

BACKGROUND ART

In recent years, a rapid spread of compact electronic device such ascellular phones and notebook personal computers created a huge demandfor nonaqueous electrolyte secondary batteries as rechargeable powersources. Lithium cobalt composite oxides represented by lithiumcobaltate (LiCoO₂) and also lithium nickel composite oxides representedby lithium nickelate (LiNiO₂) and lithium manganese composite oxidesrepresented by lithium manganate (LiMn₂O₄) have been widely used aspositive electrode active materials for the nonaqueous electrolytesecondary batteries.

The problems associated with lithium cobaltate are that it includes, asa major component, cobalt which is expensive due to scarce reserves andwhich is a metal with unstable supply and large price fluctuations.Accordingly, lithium nickel composite oxides and lithium manganesecomposite oxides containing relatively inexpensive nickel and manganeseas the main components have attracted attention due to a low costthereof.

However, although lithium manganate is superior to lithium cobaltate interms of thermal stability, the applications thereof to batteries areassociated with a large number of problems since the charge-dischargecapacity thereof is greatly inferior to that of other materials and thecharge-discharge cycle characteristic representing the service life isextremely short. Meanwhile, lithium nickelate demonstrate acharge-discharge capacity larger than that of lithium cobaltate and,therefore, is expected to be a positive electrode active materialsuitable for producing inexpensive batteries having a high energydensity.

However, lithium nickelate is usually manufactured by mixing and firinga lithium compound and a nickel compound such as nickel hydroxide andnickel oxyhydroxide, and the product is in the form of a powder withmonodispersed primary particles, or a powder of secondary particles,which are aggregates of primary particles and have voids. The drawbackof either form is that thermal stability in a charged state is inferiorto that of lithium cobaltate. Thus, pure lithium nickelate has not foundapplications in batteries for practical use due to problems associatedwith thermal stability and charge-discharge cycle characteristic. Thisis because the stability of crystal structure thereof in a charged stateis lower than that of lithium cobaltate.

This problem is typically solved by substituting part of nickel with atransition metal element such as cobalt, manganese and iron, or adissimilar element such as aluminum, vanadium, and tin, therebystabilizing the crystal structure in a state in which lithium isdesorbed in charging and producing a lithium nickel composite oxide withgood thermal stability and charge-discharge cycle characteristic for apositive electrode active material (see, for example, Patent Literature1 and Non-Patent Literature 1).

However, where the amount of the substitution element in this method issmall, thermal stability cannot be sufficiently improved, and where theamount of the substitution element is large, the capacity is decreased.Therefore, the superiority of lithium nickel composite oxide cannot berealized in batteries.

Further, where a lithium nickel composite oxide is used as is after thesynthesis involving firing, battery performance cannot be sufficientlydemonstrated in charging and discharging due to the effect of lithiumcarbonate and lithium sulfate remaining on grain boundaries or the like.For this reason, impurities have been removed by washing with water(see, for example, Patent Literature 2). Washing with water has alsobeen considered as an effective method because where the impuritiespresent on the surface are washed off, a true specific surface area isrevealed as an indicator, and correlation with thermal stability andcapacity is demonstrated (see, for example, Patent Literature 3).

However, in either case, true causes of poor battery performance andmechanisms thereof have not been sufficiently clarified and sufficientcapacity and output and excellent thermal stability could not be ensuredonly by removing the impurities and controlling the specific surfacearea. The resultant problem is that battery performance cannot be fullyutilized.

Meanwhile, lithium nickel composite oxides use an alkali such as lithiumhydroxide, and the alkali reacts with carbon dioxide in the synthesis,thereby producing lithium carbonate (Li₂CO₃). The resultant problem isthat this compound generates gas at a high temperature and causes thebattery to expand (see, for example, Non-Patent Literature 1). Further,lithium nickel composite oxides demonstrate high sensitivity to theatmosphere, and there is a concern that lithium hydroxide (LiOH)remaining on the surface even after firing could be carbonated andlithium carbonate could be further generated till the positive electrodeis completely manufactured (see, for example, Non-Patent Literature 2).

Although the improvement caused by the aforementioned washing with waterhas been investigated with respect to the improvement of thermalstability by removing surface impurities and controlling the specificsurface area, the problem of battery expanding due to gas generation hasnot been addressed.

A variety of methods for evaluating gas generation by a positiveelectrode active material have heretofore been suggested to resolve thisproblem (see, for example, Patent Literature 4 to 6).

However, the problem associated with Patent Literature 4 is that onlythe water-soluble alkali fraction revealing lithium hydroxide on thesurface is specified and a lithium carbonate fraction that causes gasgeneration at a high temperature is not specified. Further, the problemassociated with Patent Literature and Patent Literature 6 is that onlythe lithium carbonate fraction is specified and the lithium hydroxidefraction that can change into lithium carbonate before the production ofthe positive electrode is completed is not specified.

With the foregoing in view, it has been necessary to resolve theproblems inherent to the related art and to develop a positive electrodeactive material for a nonaqueous electrolyte secondary battery thatcombines a high capacity with excellent thermal stability and enables ahigh output, while clarifying true causes of poor battery performanceand mechanism thereof in a positive electrode active materialconstituted by a lithium nickel composite oxide.

CITATION LIST Patent Literature

-   Patent Literature 1: Japanese Patent Application Publication No.    H5-242891-   Patent Literature 2: Japanese Patent Application Publication No.    2003-17054-   Patent Literature 3: Japanese Patent Application Publication No.    2007-273108-   Patent Literature 4: Japanese Patent Application Publication No.    2009-140787-   Patent Literature 5: Japanese Patent Application Publication No.    2008-277087-   Patent Literature 6: Japanese Patent Application Publication No.    2009-140909

Non Patent Literature

-   Non-Patent Literature 1: High-Density Lithium Secondary Battery,    Techno System Co., Ltd., Mar. 14, 1998, pages 61 to 78-   Non-Patent Literature 2: Abstracts of Proceedings of the 47th    Battery Symposium, November 20 to 22, 2006, pages 326 to 327

SUMMARY OF INVENTION Technical Problem

In view of the above-described problems inherent to the related art, itis an object of the present invention to provide a positive electrodeactive material for a nonaqueous electrolyte secondary battery thatcombines a high capacity with excellent thermal stability and enables ahigh output, a method for producing the same, and a nonaqueouselectrolyte secondary battery having a high capacity, a high output andhigh safety that uses such positive electrode active material, whileclarifying true causes of poor battery performance and mechanismthereof.

Solution to Problem

In order to attain the above-described objects, the inventors haveconducted a comprehensive study of positive electrode active materialsfor nonaqueous electrolyte secondary batteries constituted by lithiumnickel composite oxides, and methods for producing the same. The resultsobtained have demonstrated that battery capacity, high output and gasgeneration at a high temperature of positive electrode active materialsare strongly influenced by the amount of lithium carbonate present atthe surface of lithium nickel composite oxide particles, and that a lowinternal resistance and a predetermined specific surface area can beobtained, a high capacity and a high output can be demonstrated when thepositive electrode active material is used in a battery, gas generationat a high temperature is inhibited, and excellent thermal stability canbe obtained by controlling the amount of lithium carbonate to a valueequal to or lower than a specific value. It has also been discoveredthat washing the fired powder with water under specific conditions isvery important for controlling the amount of lithium carbonate presenton the surface of lithium nickel composite oxide particles to a valueequal to or lower than a specific value, and that such washing withwater makes it possible to obtain a lithium nickel composite oxidedemonstrating excellent properties as a positive electrode activematerial for a nonaqueous electrolyte secondary battery.

Thus, according to a first aspect of the present invention, there isprovided the positive electrode active material for a nonaqueouselectrolyte secondary battery, including a lithium nickel compositeoxide represented by the following general formula (1):

General formula:Li_(b)Ni_(1-a)M1_(a)O₂  (1)

(where M1 represents at least one element selected from transition metalelements other than Ni, elements of the second group of the PeriodicSystem and elements of the thirteenth group of the Periodic System; asatisfies the condition 0.01≤a≤0.5; and b satisfies the condition0.85≤b≤1.05), wherein a specific surface area is 0.5 m²/g to 2.05 m²/gand a content of carbon in the lithium nickel composite oxide isadjusted to a value equal to or less than 0.08% by mass of a totalamount.

According to a second aspect of the present invention, there is providedthe positive electrode active material for a nonaqueous electrolytesecondary battery according to the first aspect, wherein an amount oflithium in a lithium compound present on a surface of the lithium nickelcomposite oxide is adjusted to a value equal to or less than 0.10% bymass of a total amount.

According to a third aspect of the present invention, there is providedthe positive electrode active material for a nonaqueous electrolytesecondary battery according to the first aspect, wherein the lithiumnickel composite oxide is represented by the following general formula(2):

General formula:Li_(b)Ni_(1-x-y-z)Co_(x)Al_(y)M2_(z)O₂  (2)

(where M2 is at least one element selected from the group consisting ofMn, Ti, Ca, and Mg; b satisfies the condition 0.85≤b≤1.05; x satisfiesthe condition 0.05≤x≤0.30; y satisfies the condition 0.01≤y≤0.1; and zsatisfies the condition 0≤z≤0.05).

According to a fourth aspect of the present invention, there is providedthe positive electrode active material for a nonaqueous electrolytesecondary battery according to the first aspect, wherein the content ofcarbon is 0.01% by mass to 0.04% by mass.

According to a fifth aspect of the present invention, there is providedthe positive electrode active material for a nonaqueous electrolytesecondary battery according to the second aspect, wherein the amount oflithium is a mass ratio of lithium to lithium nickel composite oxidedetermined by adding the lithium nickel composite oxide to a solution toobtain a slurry, determining an amount of an alkali fraction (lithiumcompound) by titrating a pH of the slurry with an acid under anassumption that a lithium compound present on a surface is a totalalkali fraction in the slurry, and recalculating this amount intolithium.

According to a sixth aspect of the present invention, there is providedthe positive electrode active material for a nonaqueous electrolytesecondary battery according to the fifth aspect, wherein the acid is atleast one acid selected from the group consisting of hydrochloric acid,sulfuric acid, nitric acid, and organic acids.

According to a seventh aspect of the present invention, there isprovided a method for manufacturing the positive electrode activematerial for a nonaqueous electrolyte secondary battery according to anyone of the first to sixth aspects, the method including:

(a) a step for preparing a fired powder of a lithium nickel compositeoxide represented by the following composition formula (3):

Composition formula:Li_(b)Ni_(1-a)M1_(a)O₂  (3)

(where M1 represents at least one element selected from transition metalelements other than Ni, elements of the second group of the PeriodicSystem and elements of the thirteenth group of the Periodic System; asatisfies the condition 0.01≤a≤0.5; and b satisfies the condition0.95≤b≤1.13) by mixing at least one nickel compound selected from anickel hydroxide including nickel as a main component and at least oneelement selected from other transition metal elements, elements of thesecond group of the Periodic System, and elements of the thirteenthgroup of the Periodic System as an auxiliary component, a nickeloxyhydroxide thereof, and a nickel oxide obtained by roasting thereof,and a lithium compound, and then firing the mixture at a maximumtemperature in a range of 650° C. to 850° C. under oxygen atmosphere;and

(b) a step for preparing a lithium nickel composite oxide powder bymixing the fired powder with water to obtain a slurry, washing the firedpowder with water at a temperature of 10° C. to 40° C., whilecontrolling an electrical conductivity of a liquid portion of the slurryto 30 mS/cm to 60 mS/cm, then filtering and drying the resultant firedpowder.

According to an eighth aspect of the present invention, there isprovided the method for manufacturing a positive electrode activematerial for a nonaqueous electrolyte secondary battery according to theseventh aspect, wherein in the step (b), the fired powder after waterwashing treatment is dried under a gas atmosphere including no compoundcomponent containing carbon, or under a vacuum atmosphere.

Further, according to a ninth aspect of the present invention, there isprovided the method for manufacturing a positive electrode activematerial for a nonaqueous electrolyte secondary battery according to theseventh aspect, wherein the nickel hydroxide is prepared by dropping anaqueous solution of a metal compound including nickel as a maincomponent and at least one element selected from other transition metalelements, elements of the second group of the Periodic System, andelements of the thirteenth group of the Periodic System as an auxiliarycomponent, and an aqueous solution including an ammonium ion supplyingsubstance into a heated reaction tank, and optionally dropping, asappropriate, in this process, an aqueous solution of an alkali metalhydroxide in an amount necessary to maintain a reaction solution in analkaline state.

According to a tenth aspect of the present invention, there is providedthe method for manufacturing a positive electrode active material for anonaqueous electrolyte secondary battery according to the seventhaspect, wherein the nickel oxyhydroxide is prepared by dropping anaqueous solution of a metal compound including nickel as a maincomponent and at least one element selected from other transition metalelements, elements of the second group of the Periodic System, andelements of the thirteenth group of the Periodic System as an auxiliarycomponent, and an aqueous solution including an ammonium ion supplyingsubstance into a heated reaction tank, optionally dropping, asappropriate, in this process, an aqueous solution of an alkali metalhydroxide in an amount necessary to maintain a reaction solution in analkaline state, and then adding an oxidizing agent.

According to an eleventh aspect of the present invention, there isprovided the method for manufacturing a positive electrode activematerial for a nonaqueous electrolyte secondary battery according to theseventh aspect, wherein the lithium compound is at least one selectedfrom the group consisting of lithium hydroxide, oxyhydroxide, oxide,carbonate, nitrate, and halides.

According to a twelfth aspect of the present invention, there isprovided the method for manufacturing a positive electrode activematerial for a nonaqueous electrolyte secondary battery according to theseventh aspect, wherein in step (a), a mixing ratio of the nickelcompound and lithium compound is 0.95 to 1.13 as a molar ratio of alithium amount in the lithium compound to a total amount of nickel,other transition metal elements, elements of the second group of thePeriodic System, and elements of the thirteen group of the PeriodicSystem in the nickel oxide.

According to a thirteenth aspect of the present invention, there isprovided a nonaqueous electrolyte secondary battery using the positiveelectrode active material for a nonaqueous electrolyte secondary batteryaccording to any one of the first to sixth aspects.

Advantageous Effects of Invention

According to the present invention, it is possible to obtain a positiveelectrode active material for a nonaqueous electrolyte secondary batterythat is constituted by a lithium nickel composite oxide that combines ahigh capacity with excellent thermal stability and enables a high outputwhen used in a battery. Further, the manufacturing method thereof iseasy to implement, has high productivity, and the industrial valuethereof is very high.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a cross-sectional view showing a schematic structure of a2032-type coin battery.

DESCRIPTION OF EMBODIMENTS

The positive electrode active material for a nonaqueous electrolytesecondary battery in accordance with the present invention, themanufacturing method thereof, and the nonaqueous electrolyte secondarybattery using the same will be explained in detail below.

1. Positive Electrode Active Material for Nonaqueous ElectrolyteSecondary Battery

The positive electrode active material for a nonaqueous electrolytesecondary battery in accordance with the present invention (alsoreferred to hereinbelow as “positive electrode active material inaccordance with the present invention”) is a positive electrode activematerial including a lithium nickel composite oxide represented by thefollowing general formula (1):

General formula:Li_(b)Ni_(1-a)M1_(a)O₂  (1)

(where M1 represents at least one element selected from transition metalelements other than Ni, elements of the second group of the PeriodicSystem and elements of the thirteenth group of the Periodic System; asatisfies the condition 0.01≤a≤0.5; and b satisfies the condition0.85≤b≤1.05), wherein a specific surface area is 0.5 m²/g to 2.05 m²/gand a content of carbon in the lithium nickel composite oxide isadjusted to a value equal to or less than 0.08% by mass of a totalamount.

The lithium nickel composite oxide is not particularly limited providedit is a compound represented by the general formula (1), but among suchcompounds the lithium nickel composite oxide represented by thefollowing general formula (2) is preferred:

General formula:Li_(b)Ni_(1-x-y-z)Co_(x)Al_(y)M2_(z)O₂  (2)

(where M2 is at least one element selected from the group consisting ofMn, Ti, Ca, and Mg; b satisfies the condition 0.85≤b≤1.05; x satisfiesthe condition 0.05≤x≤0.30; y satisfies the condition 0.01≤y≤0.1; and zsatisfies the condition 0≤z≤0.05).

Where lithium carbonate is present on the surface of the positiveelectrode active material constituted by the lithium nickel compositeoxide and the battery using the positive electrode active material isheld in a high-temperature state, a gas is generated due todecomposition of the lithium carbonate and the battery is expanded. As aresult, safety decreases.

Therefore, it is necessary to reduce the amount of lithium carbonate onthe positive electrode active material surface to a minimum.

The inventors have discovered a correlation between the content ofcarbon in the lithium nickel composite oxide and lithium carbonatepresent on the surface and have found out that gas generation inside thebattery can be inhibited by controlling the carbon content to a valueequal to or lower than a specific value. An especially significanteffect of inhibiting the gas generation has been confirmed in a lithiumnickel composite oxide subjected to water washing treatment.

However, it is not sufficient only to decrease the amount of lithiumcarbonate at the surface of the positive electrode active material atproduction. Thus, in the lithium nickel composite oxide constituting thepositive electrode active material in accordance with the presentinvention, excess impurities such as lithium carbonate, lithium sulfate,and lithium hydroxide generally remain on the surface thereof or on thecrystal grain boundaries. Lithium hydroxide present on the surfacereacts with carbon dioxide gas contained in the atmosphere and becomeslithium carbonate after the positive electrode active material has beenmanufactured and before it is incorporated in a battery, and the amountof lithium carbonate on the positive electrode active material surfaceincreases over that immediately after the positive electrode activematerial has been manufactured. Therefore, gas generation at a hightemperature can be inhibited more effectively by controlling not onlythe amount of lithium carbonate, but also the amount of lithiumhydroxide on the positive electrode active material surface.

In accordance with the present invention, the inhibition of gasgeneration at a high temperature is enabled by controlling the contentof carbon in the lithium nickel composite oxide to a value equal to orlower than 0.08% by mass with respect to the total amount. Where thecontent of carbon exceeds 0.08% by mass, the amount of lithium carbonatein the positive electrode active material used in a battery increases,and where lithium carbonate is exposed to a high temperature, it isdecomposed, the amount of generated gas increases, and the batterybulges. It is even more preferred that the content of carbon be equal toor less than 0.04% by mass.

Meanwhile the lower limit of the content of carbon is not particularlylimited, but it is preferred that the content of carbon be equal to orgreater than 0.01% by mass. Where the content of carbon is less than0.01% by mass, a state in which the lithium nickel composite oxide hasbeen excessively washed can be attained.

The problem arising when the lithium nickel composite oxide isexcessively washed is that lithium present in the vicinity of crystalsof the lithium nickel composite oxide is desorbed, NiO obtained byremoval of Li, or NiOOH obtained by substitution of Li with H is formedin the surface layer, and since either of them has a high electricresistance, the resistance of particle surface increases.

In the present invention, the amount of lithium means the mass ratio oflithium in the lithium compound present on the surface of lithium nickelcomposite oxide particles to the total of lithium nickel composite oxideparticles, and gas generation at a high temperature can be inhibitedmore effectively by making the amount of lithium equal to or less than0.10% by mass. Lithium compounds other than lithium hydroxide andlithium carbonate are also present on the positive electrode activematerial surface, but in the case of production under the usualconditions, a larger portion is constituted by lithium hydroxide andlithium carbonate, and by controlling the amount thereof as the amountof lithium present on the positive electrode active material surface, itis possible to inhibit gas generation at a high temperature moreeffectively.

Where the amount of lithium present on the surface exceeds 0.10% bymass, the amount of lithium carbonate in the positive electrode activematerial used in a battery increases, and where lithium carbonate isexposed to a high temperature, it is decomposed, the amount of generatedgas increases, and the battery can bulge. It is even more preferred thatthe amount of lithium be equal to or less than 0.05% by mass.

Meanwhile the lower limit of the amount of lithium present on thesurface is not particularly limited, but it is preferred that the amountof lithium be equal to or greater than 0.01% by mass. Where the amountof lithium is less than 0.01% by mass, a state in which the lithiumnickel composite oxide has been excessively washed can be attained.Thus, when the lithium nickel composite oxide powder has beenexcessively washed, a state is attained in which practically no lithiumcompound is present on the surface.

However, the amount of lithium is determined in the below-describedmanner, and in some cases, lithium is eluted in mircroamounts frominside the lithium nickel composite oxide and the amount of lithium lessthan 0.01% by mass is detected as the aforementioned amount of lithium.In the case of excess washing, a problem of the electric resistancerising on the particle surface is encountered. Another problem is thatthe amount of Li in the lithium nickel composite oxide decreases andcapacity is reduced.

The amount of lithium in the lithium compound present on the surface oflithium nickel composite oxide can be quantitatively determined bytitration with an acid using pH of the aforementioned slurry as anindicator after a solvent has been added to the lithium nickel compositeoxide and a slurry has been obtained, and the result obtained can beused to determine the mass ratio of lithium present on the surface tothe lithium nickel composite oxide.

Thus, an alkali component in the slurry is quantitatively determined inthe titration, but where the impurities contained in the lithium nickelcomposite oxide are removed, this alkali component can be considered aslithium in a lithium compound such as lithium hydroxide and lithiumcarbonate (including sodium hydrogen carbonate). Therefore, it ispossible to take the alkali component quantitatively determined byneutralization by titration as lithium in the lithium compound presenton the powder surface and determine the mass ratio of this lithium tothe lithium nickel composite oxide as the amount of lithium.

In order to prevent impurities from admixing to the slurry, it ispreferred that pure water, for example, water with 1 μS/cm or less,preferably 0.1 μS/cm or less, be used as the solvent, and the slurryconcentration is preferably such that the ratio of the solvent is 5parts by mass to 100 parts by mass per 1 part by mass of the lithiumnickel composite oxide, so as to dissolve sufficiently the lithiumcompound present on the lithium nickel composite oxide surface in thesolvent and facilitate the titration operations. Further, the acid maybe any acid that is usually used in titration, and at least one acidselected from the group consisting of hydrochloric acid, sulfuric acid,nitric acid, and organic acids is preferred.

The titration conditions may be the usual conditions used in titrationof alkaline solutions with pH as an indicator, and the equivalence pointcan be determined from the inflection point of pH. For example, theequivalence point of lithium hydroxide is close to pH 8, and theequivalence point of lithium carbonate is close to pH 4.

Physical properties of the positive electrode active material inaccordance with the present invention will be described below.

The positive electrode active material in accordance with the presentinvention is a positive electrode active material constituted by alithium nickel composite oxide powder and is obtained, for example, bymixing a fired powder having the following composition formula (3):

Composition formula(3):Li_(b)Ni_(1-a)M1_(a)O₂  (3)

(where M1 represents at least one element selected from transition metalelements other than Ni, elements of the second group of the PeriodicSystem and elements of the thirteenth group of the Periodic System; asatisfies the condition 0.01≤a≤0.5; and b satisfies the condition0.95≤b≤1.13) with water to obtain a slurry, washing the fired powderwith water at a temperature of 10° C. to 40° C., while controlling anelectrical conductivity of a liquid portion of the slurry to 30 mS/cm to60 mS/cm, then filtering and drying the resultant fired powder.

When a lithium nickel composite oxide is used as a positive electrodeactive material for a secondary battery, excess impurities such aslithium carbonate, lithium sulfate, and lithium hydroxide generallyremain on the surface thereof or on crystal grain boundaries, and alithium ion secondary battery using the positive electrode activematerial has a high internal resistance inside the battery and cannotsufficiently demonstrate the performance inherent to the material withrespect to charge-discharge efficiency and cycle performance. Bycontrast, where the impurity components present on the surface or grainboundaries are removed by water washing treatment or the like, theinternal resistance is reduced and the performance intrinsic to thebattery can be sufficiently demonstrated.

In the positive electrode active material in accordance with the presentinvention, the impurity components are removed by the aforementionedwater washing treatment at a temperature of 10° C. to 40° C. As aresult, when the positive electrode active material is used in abattery, the internal resistance is greatly reduced and a high-outputbattery can be obtained.

As for the specific surface area of the positive electrode activematerial in accordance with the present invention, the specific surfacearea after the water washing treatment is 0.5 m²/g to 2.05 m²/g. Wherethe specific surface area of the powder after the water washingtreatment is above 2.05 m²/g, the amount of heat generated by thereaction with the electrolytic solution rapidly increases and thermalstability can be decreased. Meanwhile, where the specific surface areais less than 0.5 m²/g, heat generation is inhibited, but the capacityand output characteristic of the battery can be degraded.

Further, the moisture content of the powder after drying is preferablyequal to or less than 0.2% by mass, more preferably 0.1% by mass, andstill more preferably 0.05% by mass. This is because, where the moisturecontent of the powder exceeds 0.2% by mass, gas components includingcarbon and sulfur present in the atmosphere are absorbed and a lithiumcompound can be produced on the surface, thereby causing gas generationat a high temperature. The measured value of moisture content ismeasured by a Carl Fischer moisture meter.

Further, the positive electrode active material in accordance with thepresent invention is preferably a single phase of the lithium nickelcomposite oxide having a hexagonal layered structure (hereafter it maybe simply referred to as a single phase of the lithium nickel compositeoxide). Where a foreign phase is present, battery characteristics aredegraded.

Additive elements constituting the lithium nickel composite oxiderepresented by general formula (2) above and the addition amountsthereof will be explained below.

(a) Co

Co is an additive element contributing to improvement of the cyclecharacteristic. Where the x value is less than 0.05, sufficient cyclecharacteristic cannot be obtained and the capacity retention ratedecreases as well. Where the x value exceeds 0.3, the decrease ininitial discharge capacity increases.

(b) Al

Aluminum is an additive element effective in improving safety. Where they value, which represents the addition amount thereof, is less than0.01, the addition amount is too small and the effect thereof is toolow. The y value above 0.1 is undesirable because although safetyincreases according to the addition amount, the charge-dischargecapacity decreases. In order to inhibit the decrease in charge-dischargecapacity, a range of 0.01 to 0.05 is preferred.

(c) M2

M2, as an additive element, is at least one element selected from Mn,Ti, Ca, and Mg. This element can be added to improve the cyclecharacteristic and safety. It is undesirable that z be above 0.05, sincealthough the crystal structure is further stabilized, the initialdischarge capacity is greatly decreased.

The positive electrode active material in accordance with the presentinvention is an excellent positive electrode active material for anonaqueous electrolyte secondary battery because a high capacity equalto or greater than 175 mAh/g, more preferably equal to or greater than180 mAh/g, is obtained, a high output is attained, gas generation at ahigh temperature is inhibited, and high safety is attained when thepositive electrode active material is used in a battery.

2. Method for Manufacturing Positive Electrode Active Material forNonaqueous Electrolyte Secondary Battery

The method for manufacturing the positive electrode active material inaccordance with the present invention includes the following steps (a)and (b).

(a) A step for preparing a fired powder of a lithium nickel compositeoxide represented by the following composition formula (3):

Composition formula(3):Li_(b)Ni_(1-a)M1_(a)O₂  (3)

(where M1 represents at least one element selected from transition metalelements other than Ni, elements of the second group of the PeriodicSystem and elements of the thirteenth group of the Periodic System; asatisfies the condition 0.01≤a≤0.5; and b satisfies the condition0.95≤b≤1.13) by mixing at least one nickel compound selected from anickel hydroxide including nickel as a main component and at least oneelement selected from other transition metal elements, elements of thesecond group of the Periodic System, and elements of the thirteenthgroup of the Periodic System as an auxiliary component, a nickeloxyhydroxide thereof, and a nickel oxide obtained by roasting thereof,and a lithium compound, and then firing the mixture at a maximumtemperature in a range of 650° C. to 850° C. under oxygen atmosphere(referred to hereinbelow simply as step (a), or “firing step”).

(b) A step for preparing a lithium nickel composite oxide powder bymixing the fired powder with water to obtain a slurry, washing the firedpowder with water at a temperature of 10° C. to 40° C., whilecontrolling the electrical conductivity of a liquid portion of theslurry to 30 mS/cm to 60 mS/cm, then filtering and drying the resultantfired powder (referred to hereinbelow simply as step (b) or “waterwashing and drying step”.

The steps are described below.

(a) Firing Step

The firing step (a) is a step for preparing a fired powder of a lithiumnickel composite oxide represented by the composition formula (1) aboveby mixing at least one nickel compound selected from a nickel hydroxideincluding nickel as a main component and at least one element selectedfrom other transition metal elements, elements of the second group ofthe Periodic System, and elements of the thirteenth group of thePeriodic System as an auxiliary component, a nickel oxyhydroxidethereof, and a nickel oxide obtained by roasting thereof, and a lithiumcompound, and then firing the mixture at a maximum temperature in arange of 650° C. to 850° C., preferably 700° C. to 800° C., morepreferably 755° C. to 780° C. under oxygen atmosphere.

The nickel compound used in step (a), is selected from the groupconsisting of a nickel hydroxide including nickel as a main componentand at least one element selected from other transition metal elements,elements of the second group of the Periodic System, and elements of thethirteenth group of the Periodic System as an auxiliary component, anickel oxyhydroxide thereof, and a nickel oxide obtained by roastingthereof.

Lithium nickel composite oxide obtained by a variety of methods can beused to obtain the abovementioned positive electrode active material.The preferred among them is a lithium nickel composite oxide obtained bymixing a lithium compound and a nickel compound in which a metal elementother than lithium is solid-state dissolved or dispersed by acrystallization method, and firing the mixture.

Thus, typical methods for manufacturing a lithium nickel composite oxideinclude a method of using a lithium compound and a nickel compound inwhich a metal element other than lithium is solid-state dissolved ordispersed by a crystallization method as starting materials, mixing thestarting materials, and firing the mixture, a method of mixing all ofthe aqueous solutions including the desired metal elements, andsubjecting the liquid mixture of spray pyrolysis treatment, and a methodof pulverizing and mixing all of the compounds of the desired metalelements by mechanical pulverization such as ball milling and thenfiring the mixture.

However, among those methods, in methods other than those in which thenickel starting material is manufactured by a crystallization method,the specific surface area of the obtained lithium nickel composite oxideis very large and, therefore, a problem is associated with thermalstability and the methods are inefficient. Further, where thecrystallization method is used, a nickel hydroxide or nickeloxyhydroxide, which is a nickel compound forming spherical particleswith an advantageously high bulk density, can be manufactured as apositive electrode active material. Therefore, such compounds, alsoinclusive of nickel oxide obtained by roasting thereof, are alsoadvantageous in terms of filling ability. Accordingly, thecrystallization method is most suitable for manufacturing lithium nickelcomposite oxides.

Nickel hydroxide to be used in the above-described step (a) is notparticularly limited, and the compounds obtained by the crystallizationmethod under a variety of conditions can be used. The preferred amongthem is prepared, for example, by dropping an aqueous solution of ametal compound including nickel as a main component and at least oneelement selected from other transition metal elements, elements of thesecond group of the Periodic System, and elements of the thirteenthgroup of the Periodic System as an auxiliary component, and an aqueoussolution including an ammonium ion supplying substance into a reactiontank heated preferably to 40° C. to 60° C., and optionally dropping, asappropriate, in this process, an aqueous solution of an alkali metalhydroxide in an amount necessary to maintain a reaction solution in analkaline state, preferably at a pH of 10 to 14. Thus, nickel hydroxidemanufactured by this method is a powder with a high bulk density and,therefore, is advantageous as a starting material for a lithium nickelcomposite oxide to be used for a positive electrode active material fora nonaqueous electrolyte secondary battery.

Where the temperature exceeds 60° C. or pH exceeds 14, priority ofnucleation in the liquid increases, crystal growth does not advance, andonly a fine powder is obtained. Meanwhile, the problem arising when thetemperature is less than 40° C. or pH is less than 10 is that nucleationin the liquid decreases, crystal growth of grains becomes a priorityand, therefore, very large particles, such that cause depressions andprotrusions in the electrode fabrication process, are produced, or theresidual amount of metal ions in the reaction liquid increases, therebyleading to extremely poor reaction efficiency.

The nickel oxyhydroxide to be used in the abovementioned step (a) is notparticularly limited, but the preferred nickel oxyhydroxide is preparedby further adding an oxidizing agent such as sodium hyperchlorite andhydrogen peroxide to the nickel hydroxide. Thus, the nickel oxyhydroxideproduced by this method is a powder with a high bulk density and,therefore, advantageous as a staring material for the lithium nickelcomposite oxide to be used for the positive electrode active materialfor a nonaqueous electrolyte secondary battery.

The nickel oxide to be used in the abovementioned step (a) is notparticularly limited, but the preferred nickel oxide is obtained byroasting the above-described nickel hydroxide or nickel oxyhydroxide.The roasting conditions of the nickel hydroxide or nickel oxyhydroxideare not particularly limited, and it is desirable that roasting beperformed, for example, under air atmosphere at a temperature ofpreferably 500° C. to 1100° C., more preferably 600° C. to 1000° C., andeven more preferably 650° C. to 745° C. In this case, where the roastingtemperature is below 500° C., quality of the lithium nickel compositeoxide obtained by using the roasted material is difficult to stabilize,and a heterogeneous composition is easily formed in synthesis.Meanwhile, where the roasting temperature is higher than 1100° C.,primary particles constituting the particles start growing rapidly andthe reaction surface area on the nickel compound side in the subsequentpreparation of lithium nickel composite oxide becomes too small. Theresultant problem is that the reaction with lithium is inhibited andspecific gravity separation proceeds into the nickel compound with ahigh specific gravity in the lower layer and a lithium compound in amolten state in the upper layer.

In the manufacturing method in accordance with the present invention,the fired powder of the lithium nickel composite oxide represented bycomposition formula (1) above is prepared by mixing at least one nickelcompound selected from the nickel hydroxide, a nickel oxyhydroxidethereof, and a nickel oxide obtained by roasting thereof, and a lithiumcompound, and then firing the mixture at a maximum temperature in arange of 650° C. to 850° C., preferably 700° C. to 800° C., and evenmore preferably 755° C. to 780° C. under oxygen atmosphere.

In the abovementioned mixing, a dry mixing machine or a mixinggranulator such as a V blender is used. Further, in the abovementionedfiring, a firing furnace such as an electric furnace, a kiln, a tubularfurnace, and a pusher furnace is used, the furnace having a gasatmosphere adjusted to an oxygen concentration equal to or higher than20% by mass, such as oxygen atmosphere or dry air atmosphere afterdehumidification and removal of carbon dioxide removal treatment.

The abovementioned lithium compound is not particularly limited, and atleast one compound selected from the group consisting of lithiumhydroxide, oxyhydroxide, oxide, carbonate, nitrate, and halides can beused.

The mixing ratio of the nickel compound and the lithium compound in step(a) is not particularly limited, but is preferably adjusted, forexample, such that a molar ratio of the lithium amount in the lithiumcompound to a total amount of nickel, other transition metal elements,elements of the second group of the Periodic System, and elements of thethirteen group of the Periodic System in the nickel oxide is 0.90 to1.10.

Thus, where the molar ratio is less than 0.95 the molar ratio of theresultant fired powder is also less than 0.95, very poor crystallinityis obtained, and a molar ratio (b) of lithium and a metal other thanlithium after water washing is less than 0.85, thereby causing a largedecrease in battery capacity in charge-discharge cycling. Meanwhile,where the molar ratio is greater than 1.13, the molar ratio of theresultant fired powder is also greater than 1.13, an excess lithiumcompound is present in a large amount on the surface and this compoundis difficult to remove by water washing. Therefore, where the firedpowder is used as a positive electrode active material, a large amountof gas is generated when the battery is charged. Furthermore, since thepowder has a high pH, it reacts with other materials, such as an organicsolvent, used in electrode fabrication, and the slurry is gelled,thereby causing troubles. Further, where the molar ratio (b) after waterwashing exceeds 1.05, the internal resistance of the positive electrodein the battery increases.

A maximum temperature in a range of 650° C. to 850° C., preferablywithin a range of 700° C. to 800° C., and even more preferably 755° C.to 780° C. is used as the firing temperature. Thus, where the heattreatment is performed at a temperature higher than 500° C., lithiumnickelate is generated, but at a temperature below 650° C., the crystalsthereof are undeveloped and structurally unstable, and the structure iseasily destroyed by phase transition caused by charging and discharging.Meanwhile, where the temperature exceeds 850° C., the layered structurecollapses, lithium ions are unlikely to be introduced and detached, andnickel oxide or the like is formed by decomposition. Further, in orderto ensure a uniform reaction in a temperature region in which crystalgrowth proceeds after the water of crystallization of the lithiumcompound has been removed, it is especially preferred that the firing beperformed in two stages, that is, by prefiring for 1 h or longer at atemperature of 400° C. to 600° C. and then by firing for 3 h or longerat a temperature of 650° C. to 850° C.

(b) Water Washing and Drying Step

In step (b), the fired powder is washed and then filtered and dried.

In the water washing treatment of the fired powder, it is important thatthe fired powder be mixed with water to obtain a slurry and that theelectrical conductivity of the liquid portion of the slurry becontrolled to 30 mS/cm to 60 mS/min (can be also referred to hereinbelowas “liquid electrical conductivity”) within a temperature range of 10°C. to 40° C., preferably 15° C. to 30° C.

By controlling the slurry temperature to 10° C. to 40° C. and the liquidelectrical conductivity to 30 mS/cm to 60 mS/cm in the water washingtreatment, it is possible to reduce the amount of lithium present on thesurface of the lithium nickel composite oxide powder to a value equal toor less than 0.10% by mass and inhibit gas generation during storing ata high temperature. Further, it is possible to obtain a positiveelectrode active material in which a high capacity and a high output canbe attained and also ensure high safety.

By contrast, where the water washing temperature is less than 10° C. orthe liquid electrical conductivity is higher than 60 mS/cm, waterwashing is insufficient, and the impurities that have adhered to thefired powder surface cannot be removed and remain in a large amount. Theimpurities include lithium carbonate and lithium hydroxide, and thestate is attained in which the carbon content in the lithium nickelcomposite oxide powder exceeds 0.08% by mass and gas generation easilyoccurs during storage at a high temperature. Further, since theremaining impurities increase the surface resistance, the resistancevalue increases when the powder is used for a positive electrode of abattery. In addition, the specific surface area becomes too small.

Meanwhile, where the water washing temperature exceeds 40° C., theamount of lithium eluting from the fired powder increases and lithiumconcentration in the washing liquid increases. As a result, the amountof lithium adhering again as lithium hydroxide to the powder surfaceincreases, lithium hydroxide is carbonated in the air after the washing,and the carbon content exceeds 0.08% by mass. Further, sinceover-washing is performed and the specific surface area after the waterwashing treatment becomes too large, the amount of heat generated by thereaction with the electrolytic solution is thereby increased and thermalstability is decreased. In addition, NiO obtained by removal of Li, orNiOOH obtained by substitution of Li with H is formed in the surfacelayer, and since either of them has a high electric resistance, theresistance of particle surface increases, the amount of Li in thelithium nickel composite oxide decreases, and capacity decreases.

When the liquid electrical conductivity is less than 30 mS/cm,over-washing occurs and the over-washing causes problems.

The liquid electrical conductivity is affected by the slurry temperatureand the content of lithium in the fired powder to be subjected to waterwashing treatment, and especially by the excess amount of lithiumpresent on the particle surface, but can be controlled by the slurryconcentration during the water washing treatment. Where the slurryconcentration is decreased, the liquid electrical conductivitydecreases, and where the slurry concentration is increased, the liquidelectrical conductivity also increases. However, where the content oflithium in the fired powder and the production conditions are constant,the same slurry temperature and concentration ensure the same liquidelectrical conductivity. Therefore, the liquid electrical conductivitycan be easily controlled by determining the water washing conditions bypreliminary tests, such as to obtain an optimum liquid electricalconductivity. The liquid electrical conductivity can be determined bymeasuring with conductance meter the electrical conductivity of theliquid portion obtained by solid-liquid separation of part of the slurryin this step, or the filtrate after the washing.

In accordance with the present invention, it is important to control theliquid electrical conductivity during the water washing treatment, butit is also effective to control the slurry concentration. Thus, it ispreferred that the amount (g) of the fired powder per 1 L of watercontained in the slurry be 500 g/L to 2000 g/L, more preferably 500 g/Lto 1500 g/L, as the slurry concentration during water washing. Thus, thehigher is the slurry concentration, the larger is the amount of thepowder, and where the concentration exceeds 2000 g/L, the viscosity alsobecomes very high. As a result, not only the stirring becomes difficult,but because the amount of alkali in the liquid is high, the dissolutionrate of the adhered matter decreases with respect to that in theequilibrium relationship, and even if peeling occurs, the adhered matteris unlikely to be separated from the powder. Meanwhile, where the slurryconcentration is less than 500 g/L, the slurry is overdiluted and,therefore, the elution amount of lithium increases and the amount oflithium on the surface decreases. However, lithium is also detached frominside the crystal lattice of the positive electrode active material,and the crystals easily collapse, or a high-pH aqueous solution absorbscarbon dioxide contained in the air, thereby causing reprecipitation oflithium carbonate. Further, where productivity is considered from theindustrial standpoint, in terms of equipment capacity and operability,it is desirable that the slurry concentration be 500 g/L to 2000 g/L.For example, in the process described in Japanese Patent ApplicationPublication No. 2004-171961, washing is performed at a dilute slurryconcentration of 40 g/L to evaluate the positive electrode activematerial, but the liquid electrical conductivity becomes too low at sucha slurry concentration.

Further, the water washing time is not particularly limited, but itshould be sufficient for the content of carbon in the lithium nickelcomposite oxide to become equal to or less than 0.08% by mass withrespect to the total amount. The water washing time is usually 20 min to2 h, but cannot be determined unconditionally because it depends onwater washing temperature and electrical conductivity of the filtrate.

Water to be used in not particularly limited, but water with a measuredelectrical conductivity below 10 μS/cm is preferred, and water with ameasured electrical conductivity equal to or less than 1 μS/cm is morepreferred. Thus, the water with a measured electrical conductivity below10 μS/cm makes it possible to prevent the degradation of batteryperformance caused by the adhesion of impurities to the positiveelectrode active material.

It is preferred that the amount of adhered water remaining on theparticle surface during solid-liquid separation of the slurry be small.Where the amount of adhered water is large, lithium that has dissolvedin the liquid reprecipitates, lithium present on the surface of thelithium nickel composite oxide powder during drying is carbonated andthe content of carbon can increase. It is usually preferred that thecontent of the adhered water be 1% by mass to 10% by mass with respectto the lithium nickel composite oxide powder.

The drying temperature is not particularly limited, but is preferably80° C. to 700° C., more preferably 100° C. to 550° C., even morepreferably 120° C. to 350° C. Thus, the drying temperature is set to beequal to or higher than 80° C. in order to dry rapidly the positiveelectrode active material after washing with water and prevent theoccurrence of lithium concentration gradient between the particlesurface and the inside of the particles. Meanwhile, since it can beassumed that a state very close to a stoichiometric state or close to acharged state realized by a certain detachment of lithium is attainedclose to the surface of the positive electrode active material, thetemperature in excess of 700° C. can induce the collapse of the crystalstructure of the powder close to the charged state and degrade theelectric characteristics. Further, to alleviate concerns about physicalproperties and characteristics of the positive electrode active materialafter washing with water, it is desirable that the temperature be 100°C. to 550° C., and in order to improve productivity and reduce thermalenergy cost, it is desirable that the temperature be 120° C. to 350° C.In this case, it is preferred that the powder after the filtration bedried at a predetermined temperature by using a drying apparatus whichcan be controlled to a gas atmosphere including no compound componentcontaining carbon or sulfur, or under a vacuum atmosphere. Inparticular, the increase in the content of carbon in the lithium nickelcomposite oxide can be inhibited by drying under the atmosphereincluding no compound component containing carbon.

3. Nonaqueous Electrolyte Secondary Battery

The nonaqueous electrolyte secondary battery in accordance with thepresent invention is a high-capacity and high-safety nonaqueouselectrolyte secondary battery incorporating a positive electrodefabricated using a positive electrode active material constituted by thelithium nickel composite oxide, in particular by using the lithiumnickel composite oxide obtained by the abovementioned manufacturingmethod as a positive electrode active material.

In accordance with the present invention, properties of the activematerial itself are improved. Therefore, the performance of the batteryobtained by using the active material does not depend on the shapethereof. Thus, the battery shape is not limited to the coin batteryshown in the examples and may be a cylindrical or angular shape obtainedby winding band-shaped positive electrode and negative electrode with aseparator interposed therebetween.

A method for fabricating a positive electrode to be used in thenonaqueous electrolyte secondary battery in accordance with the presentinvention will be explained below, but this method is not particularlylimiting. For example, a positive electrode is fabricated in which apositive electrode mix including positive electrode active materialparticles and a binder is supported on a band-shaped positive electrodecore material (positive electrode collector). The positive electrode mixcan also include an additive such as a conductive material as anoptional component. In order to support the positive electrode mix onthe core material, the positive electrode mix is dispersed in a liquidcomponent to prepare a paste, and the paste is coated on the corematerial and dried.

A thermoplastic resin or a thermosetting resin may be used as the binderfor the positive electrode mix, but the thermoplastic resin ispreferred.

Examples of thermoplastic resins include polyethylene, polypropylene,polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), astyrene-butadiene rubber, a tetrafluoroethylene-hexafluoropropylenecopolymer (FEP), a tetrafluoroethylene-perfluoroalkyl vinyl ethercopolymer (PFA), a vinylidene fluoride hexafluoropropylene copolymer, avinylidene fluoride chlorotrifluoroethylene copolymer, an ethylenetetrafluoroethylene copolymer (ETFE), polychlorotrifluoroethylene(PCTFE), a vinylidene fluoride-pentafluoropropylene copolymer, apropylene-tetrafluoroethylene copolymer, an ethylenechlorotrifluoroethylene copolymer (ECTFE), a vinylidenefluoride-hexafluoropropylene-tetrafluoroethylene copolymer, a vinylidenefluoride perfluoromethyl vinyl ether-tetrafluoroethylene copolymer, anethylene-acrylic acid copolymer, an ethylene-methacrylic acid copolymer,an ethylene methyl acrylate copolymer, and an ethylene-methylmethacrylate copolymer. Those compounds may be used individually or incombinations of two or more thereof. In addition, they may becrosslinked by Na⁺ ions or the like.

Any electron conductive material which is chemically stable inside thebattery can be used as the electrically conductive material of thepositive electrode mix. Examples of suitable materials include graphitesuch as natural graphite (flaky graphite and the like) and artificialgraphite; carbon black such as acetylene black, Ketjen black, channelblack, furnace black, lamp black, and thermal black; conductive fiberssuch as carbon fibers and metallic fibers; metal powders such asaluminum; conductive whiskers such as zinc oxide and potassium titanate;a conductive metal oxide such as titanium oxide; organic conductivematerials such as polyphenylene derivatives; and carbon fluoride. Thosematerials may be used individually or in combinations of two or morethereof.

The addition amount of the electrically conductive material of thepositive electrode mix is not particularly limited, and it is preferably0.5% by mass to 50% by mass, more preferably 0.5% by mass to 30% bymass, and still more preferably 0.5% by mass to 15% by mass, withrespect to the positive electrode active material particles contained inthe positive electrode mix.

Any positive electrode core material (positive electrode collector) maybe used, provided that it is an electron conductive material that ischemically stable inside the battery. For example, a foil or a sheetconstituted by aluminum, stainless steel, nickel, titanium, carbon, or aconductive resin can be used. Among them, an aluminum foil and analuminum alloy foil are preferred. In this case, it is also possible toprovide a carbon or titanium layer, or form an oxide layer on thesurface of the foil or sheet. Further, depressions and protrusions canbe formed on the surface of the foil or sheet, and it is also possibleto use a net, a punching sheet, a lath material, a porous material, afoamed material, or a material obtained by molding a group of fibers.

The thickness of the positive electrode core material is notparticularly limited, and can be, for example, 1 μm to 500 μm.

Constituent elements, other than the positive electrode, that are to beused in the nonaqueous electrolyte secondary battery in accordance withthe present invention will be explained below. Since the specificfeature of the nonaqueous electrolyte secondary battery in accordancewith the present invention is in the use of the abovementioned positiveelectrode active material, other constituent elements are notparticularly limited.

A material capable of charging and discharging lithium is used as anegative electrode. For example, a negative electrode prepared bysupporting a negative electrode mix including a negative electrodeactive material and a binder and also an electrically conductivematerial and a thickening agent as optional components on a negativeelectrode core material can be used. Such a negative electrode can befabricated by the same method as the positive electrode.

A material capable of electrochemically charging and discharging lithiummay be used as the negative electrode active material. For example,graphite, hardly graphitizable carbon materials, and lithium alloys canbe used. Among the lithium alloys those including at least one elementselected from the group consisting of silicon, tin, aluminum, zinc andmagnesium are particularly preferred.

The mean particle size of the negative electrode active material is notparticularly limited and may be, for example, 1 μm to 30 μm

A thermoplastic resin or a thermosetting resin may be used as a binderfor the negative electrode mix, but the thermoplastic resin ispreferred. Examples of thermoplastic resins include polyethylene,polypropylene, polytetrafluoroethylene (PTFE), polyvinylidene fluoride(PVDF), a styrene-butadiene rubber, atetrafluoroethylene-hexafluoropropylene copolymer (FEP), atetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), avinylidene fluoride-hexafluoropropylene copolymer, a vinylidene fluoridechlorotrifluoroethylene copolymer, an ethylene tetrafluoroethylenecopolymer (ETFE), polychlorotrifluoroethylene (PCTFE), a vinylidenefluoride pentafluoropropylene copolymer, a propylene-tetrafluoroethylenecopolymer, an ethylene chlorotrifluoroethylene copolymer (ECTFE), avinylidene fluoride hexafluoropropylene tetrafluoroethylene copolymer, avinylidene fluoride perfluoromethyl vinyl ether-tetrafluoroethylenecopolymer, an ethylene-acrylic acid copolymer, an ethylene-methacrylicacid copolymer, an ethylene-methyl acrylate copolymer, and anethylene-methyl methacrylate copolymer. Those compounds may be usedindividually or in combinations of two or more thereof. In addition,they may be crosslinked by Na⁺ ions or the like.

Any electron conductive material which is chemically stable inside thebattery can be used as the electrically conductive material of thenegative electrode mix. Examples of suitable materials include graphitesuch as natural graphite (flaky graphite and the like) and artificialgraphite; carbon black such as acetylene black, Ketjen black, channelblack, furnace black, lamp black, and thermal black; conductive fiberssuch as carbon fiber and metallic fiber; metal powders such as copperand nickel; and organic conductive materials such as polyphenylenederivatives. Those materials may be used individually or in combinationsof two or more thereof.

The addition amount of the electrically conductive material of thenegative electrode mix is not particularly limited, and it is preferably1% by mass to 30% by mass, more preferably 1% by mass to 10% by masswith respect to the negative electrode active material particlescontained in the negative electrode mix.

Any negative electrode core material (negative electrode collector) maybe used, provided that it is an electron conductive material that ischemically stable inside the battery. For example, a foil or a sheetconstituted by stainless steel, nickel, copper, titanium, carbon, or aconductive resin can be used. Among them, a copper foil and a copperalloy foil are preferred. In this case, it is also possible to provide acarbon, titanium, or nickel layer, or form an oxide layer on the surfaceof the foil or sheet. Further, depressions and protrusions can be formedon the surface of the foil or sheet, and it is also possible to use anet, a punching sheet, a lath material, a porous material, a foamedmaterial, or a material obtained by molding a group of fibers.

The thickness of the negative electrode core material is notparticularly limited, and can be, for example, 1 μm to 500 μm.

A nonaqueous solvent having a lithium salt dissolved therein ispreferred as a nonaqueous electrolytic solution.

Examples of suitable nonaqueous solvents include cyclic carbonates suchas ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate(BC), and vinylene carbonate (VC); chain carbonates such as dimethylcarbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC),and dipropyl carbonate (DPC); aliphatic carboxylic acid esters such asmethyl formate, methyl acetate, methyl propionate, and ethyl propionate;lactones such as γ-butyrolactone, γ-valerolactone; chain ethers such as1,2-dimethoxyethane (DME), 1,2-diethoxyethane (DEE), and ethoxy methoxyethane (EME); cyclic ethers such as tetrahydrofuran and2-methyltetrahydrofuran; dimethylsulfoxide, 1,3-dioxolane, formamide,acetamide, dimethylformamide, dioxolane, acetonitrile, propylnitrile,nitromethane, ethylmonoglyme, triester phosphate, trimethoxymetane,dioxolane derivatives, sulfolane, methylsulfolane,1,3-dimethyl-2-imidazolidinone, 3-methyl-2-oxazolidinone, propylenecarbonate derivatives, tetrahydrofuran derivatives, ethyl ether,1,3-propane sultone, anisole, dimethylsulfoxide, andN-methyl-2-pyrrolidone. Those compounds may be used individually or incombinations of two or more thereof. Among them, a mixed solvent of acyclic carbonate and a chain carbonate, and a mixed solvent of a cycliccarbonate, a chain carbonate and an aliphatic carboxylate are preferred.

Examples of suitable lithium salts include LiClO₄, LiBF₄, LiPF₆,LiAlCl₄, LiSbF₆, LiSCN, LiCl, LiCF₃SO₃, LiCF₃CO₂, Li (CF₃SO₂)₂, LiAsF₆,LiN (CF₃SO₂)₂, LiB₁₀Cl₁₀, lithium salts of lower aliphatic carboxylicacids, LiBr, LiI, chloroborane lithium, lithium tetraphenylborate, andlithium imide salts. Those salts may be used individually or incombinations of two or more thereof. It is preferred that at least LiPF₆be used.

The concentration of the lithium salt in the nonaqueous solvent is notparticularly limited, but is preferably 0.2 mol/L to 2 mol/L, and morepreferably 0.5 mol/L to 1.5 mol/L.

A variety of additives can be added to the nonaqueous electrolyticsolution to improve the charge-discharge characteristics of the battery.Examples of the additives include triethyl phosphite, triethanolamine,cyclic ethers, ethylene diamine, n-glyme, pyridine, hexaphosphoric acidtriamide, nitrobenzene derivatives, crown ethers, quaternary ammoniumsalts, and ethylene glycol dialkyl ethers.

Further, a separator is interposed between the positive electrode andthe negative electrode. The separator is preferably a microporous thinmembrane having large ion permeability and a predetermined mechanicalstrength, as well as electric insulation ability. The microporous thinmembrane preferably has a function of closing pores and increasing theelectric resistance at a temperature equal to or higher than a certaintemperature. It is also preferred that a polyolefin such aspolypropylene and polyethylene having excellent resistance to organicsolvents and hydrophobic property be used as a material for themicroporous thin membrane. In addition, a sheet, nonwoven fabric, orwoven fabric made of glass fiber can be also used.

A pore size of the separator is, for example, 0.01 μm to 1 μm. Theseparator thickness is typically 10 μm to 300 μm. A void ratio of theseparator is typically at 30% to 80%.

Further, a polymer electrolyte constituted by a nonaqueous electrolyticsolution and a polymer material holding the same can be also usedintegrally with the positive electrode or negative electrode as theseparator. The polymer material is not particularly limited, providedthat it is capable of holding the nonaqueous electrolytic solution, buta copolymer of vinylidene fluoride and hexafluoropropylene isparticularly preferred.

EXAMPLES

The present invention will be explained below in greater detail on thebasis of examples of the present invention and comparative examples, butthe present invention is not limited to the examples. The followingmethods were used for analyzing metals in the lithium nickel compositeoxides used in the examples and comparative examples and for evaluatingthe specific surface area.

(1) Analysis of metals was conducted by IPC emission spectrometry.

(2) Analysis of carbon was conducted by high-frequencycombustion-infrared absorption method.

(3) The specific surface area was measured by a BET method.

Example 1

A positive electrode active material constituted by a lithium nickelcomposite oxide was produced by a series of steps including: a step forpreparing a nickel hydroxide having a predetermined compositiondescribed hereinbelow, a step for preparing a fired powder having apredetermined composition, and a step for water washing the resultantfired powder and then drying, and then a coin battery was fabricatedusing the dried powder as a positive electrode material. The battery wasevaluated by the impedance thereof.

The starting materials were weighted such that molar ratios of the metalcomponents of the lithium nickel composite oxide wereNi:Co:Al:Li=0.82:0.15:0.03:1.02.

(1) Step for Preparing Nickel Hydroxide

Firstly, an aqueous solution was prepared by mixing nickel sulfatehexahydrate (produced by Wako Pure Chemical Industries, Ltd.), cobaltsulfate heptahydrate (produced by Wako Pure Chemical Industries, Ltd.)and aluminum sulfate (produced by Wako Pure Chemical Industries, Ltd.)at desired ratios. This aqueous solution was dropped simultaneously withammonia water (produced by Wako Pure Chemical Industries, Ltd.) and anaqueous solution of sodium hydroxide (produced by Wako Pure ChemicalIndustries, Ltd.) into a stirring reaction tank equipped with adischarge outlet and filled with water warmed to 50° C. In this case,spherical nickel hydroxide constituted by aggregated primary particleswas produced by a reaction crystallization method in which pH wasmaintained at 11.5 and a residence time was controlled to 11 hours.

(2) Step for Producing Fired Powder

Lithium hydroxide monohydrate (produced by Wako Pure ChemicalIndustries, Ltd.) was added to the resultant nickel hydroxide so as toattain the desired composition, and the components were mixed using aV-blender. The mixture obtained was prefired for 3 hours at 500° C.under an atmosphere with an oxygen concentration equal to or higher than30% by using an electric furnace, and then subjected to main firing for20 hours at 760° C. The fired product was cooled to room temperatureinside the furnace and then pulverized to obtain a spherical firedpowder constituted by aggregated primary particles.

(3) Step for Water Washing and Drying the Fired Powder

A slurry was prepared by adding pure water at 20° C. to the resultantfired powder so as to obtain the liquid electrical conductivity of theslurry of 45 mS/cm, and the slurry was stirred for 50 minutes and washedwith water, and then filtered. The powder was taken out and allowed tostay for 10 hours using a vacuum drying machine warmed to 150° C. Then,the composition of the lithium nickel composite oxide powder and thecarbon content (TC) thereof were analyzed and the specific surface areathereof was measured. The lithium nickel composite oxide was confirmedto be a single phase by powder X-ray diffraction using Cu-Kα ray. Theresults are shown in Table 2.

(4) Fabrication and Evaluation of Battery

A battery was fabricated by the following method by using the resultantlithium nickel composite oxide, and the internal resistance was measuredby the battery impedance. The results are shown in Table 2.

[Battery Fabrication Method]

A total of 5 parts by mass of acetylene black and 5 parts by mass ofpolyvinylidene fluoride were mixed with 90 parts by mass of the positiveelectrode active material powder, and a paste was obtained by addingn-methylpyrrolidone. The paste was applied onto an aluminum foil with athickness of 20 μm to obtain a weight of the active material afterdrying of 0.05 g/cm², vacuum drying was performed at 120° C., and then adisk with a diameter of 1 cm was punched out therefrom to obtain apositive electrode.

Metallic lithium was used as a negative electrode and a solutionprepared by mixing ethylene carbonate (EC) and diethyl carbonate (DEC)in equal amounts and containing 1M LiClO₄ as a supporting electrolytewas used as an electrolytic solution. The electrolytic solution wasinfiltrated into a separator made of polyethylene, and a 2032-type coinbattery was fabricated in a glove box under an Ar gas atmospherecontrolled at a dew point of −80° C.

FIG. 1 shows a schematic structure of the 2032-type coin battery. Thecoin battery is composed of a positive electrode (electrode forevaluation) 1 in a positive electrode can 5, a lithium metal negativeelectrode 3 in a negative electrode can 6, a separator 2 infiltratedwith the electrolytic solution, and a gasket 4.

[Method for Evaluation by Impedance]

The fabricated battery was allowed to stay for about 24 hours tostabilize OCV, and then CCCV charging was performed up to a voltage of4.0 V at an initial current density of 0.5 mA/cm², relative to thepositive electrode. The charged coin battery was then used to performimpedance measurements by scanning from a frequency of 10 kHz to afrequency of 0.1 Hz under a voltage condition of 10 mV. The impedancedevice used in this case was an impedance analyzer 1255B, manufacturedby Solartron Co., Ltd.

The internal resistance value Rct shown in Table 1 was calculated fromthe second arc after the measurements and expressed as a relative valuefor which the value obtained in Example 1 was taken as 100.

[Measurement of Amount of Lithium at the Surface]

Ultra-pure water was added up to 100 ml to 10 g of the lithium nickelcomposite oxide powder, followed by stirring and then titration with 1mol/L of hydrochloric acid. The measurements were conducted up to thesecond neutralization point. The alkali component neutralized byhydrochloric acid was assumed to be lithium on the surface of thelithium nickel composite oxide, a mass ratio of lithium to the lithiumnickel composite oxide was determined from the titration result, andthis value was taken as the amount of lithium at the surface. Theresults are shown in Table 2.

[Measurement of Gas Generation Amount at High Temperature]

The gas generation amount was measured by allowing the fabricatedbattery to stay in a charged state for 24 hours at a high temperature of80° C., cutting a part of an exterior packaging of the battery, andquantitatively determining the volume of gas replaced and collected onthe liquid in paraffin at 23° C. The results are shown in Table 2.

Example 2

A lithium nickel composite oxide was produced similarly as in Example 1,except that nickel oxyhydroxide obtained by further adding sodiumhypochlorite and performing the oxidation treatment was used instead ofnickel hydroxide obtained in (1) Step for Preparing Nickel Hydroxide ofExample 1.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 3

A lithium nickel composite oxide was produced similarly as in Example 1,except that nickel hydroxide obtained in (1) Step for Preparing NickelHydroxide of Example 1 was oxidation roasted at 740° C. to obtain nickeloxide.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 4

A lithium nickel composite oxide was produced similarly as in Example 3,except that a mixture of aqueous solutions of starting materials wasprepared by mixing nickel sulfate hexahydrate (produced by Wako PureChemical Industries, Ltd.), cobalt sulfate heptahydrate (produced byWako Pure Chemical Industries, Ltd.), aluminum sulfate (produced by WakoPure Chemical Industries, Ltd.) and magnesium sulfate heptahydrate(produced by Pure Chemical Co., Ltd.) to obtain the molar ratiosNi:Co:Al:Mg:Li=0.804:0.148:0.036:0.012:1.02 of metal components of thelithium nickel composite oxide after firing.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 5

A lithium nickel composite oxide was produced similarly as in Example 3,except that a mixture of aqueous solutions of starting materials wasprepared by mixing nickel sulfate hexahydrate (produced by Wako PureChemical Industries, Ltd.), cobalt sulfate heptahydrate (produced byWako Pure Chemical Industries, Ltd.), aluminum sulfate (produced by WakoPure Chemical Industries, Ltd.) and manganese sulfate pentahydrate(produced by Pure Chemical Co., Ltd.) to obtain the molar ratiosNi:Co:Al:Mn:Li=0.786:0.151:0.035:0.028:1.02 of metal components of thelithium nickel composite oxide after firing.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 6

A lithium nickel composite oxide was produced similarly as in Example 3,except that lithium oxide was used instead of lithium hydroxidemonohydrate described in Example 1.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 7

A lithium nickel composite oxide was produced similarly as in Example 3,except that the main firing temperature in the step for preparing thefired powder described in Example 1 was 700° C. Results of measuring thecomposition of the resultant powder, carbon content therein, amount oflithium at the surface, specific surface area, battery impedance, andamount of gas generated during high-temperature storage are shown inTables 1 and 2. The lithium nickel composite oxide was confirmed to be asingle phase by powder X-ray diffraction using Cu-Kα ray.

Example 8

A lithium nickel composite oxide was produced similarly as in Example 3,except that the main firing temperature in the step for preparing thefired powder described in Example 1 was 800° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 9

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 15° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 10

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 30° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 11

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 35° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 12

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 12° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 13

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 38° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 14

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 10° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Example 15

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 40° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Comparative Example 1

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 0° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Comparative Example 2

A lithium nickel composite oxide was produced similarly as in Example 3,except that the temperature of pure water used in water washing in thestep for water washing and drying the fired powder described in Example1 was 50° C.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Comparative Example 3

A lithium nickel composite oxide was produced similarly as in Example 3,except that the amount of pure water added in the step for water washingand drying the fired powder described in Example 1 was adjusted and theliquid electrical conductivity of the slurry was adjusted to 70 mS/cm.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

Comparative Example 4

A lithium nickel composite oxide was produced similarly as in Example 3,except that the amount of pure water added in the step for water washingand drying the fired powder described in Example 1 was adjusted and theliquid electrical conductivity of the slurry was adjusted to 20 mS/cm.

Results of measuring the composition of the resultant powder, carboncontent therein, amount of lithium at the surface, specific surfacearea, battery impedance, and amount of gas generated duringhigh-temperature storage are shown in Tables 1 and 2. The lithium nickelcomposite oxide was confirmed to be a single phase by powder X-raydiffraction using Cu-Kα ray.

TABLE 1 Water Electric Nickel Oxide Li Firing washing conductivitystarting Chemical composition starting temperature temperature offiltrate material form after firing material (° C.) (° C.) (mS/cm)Example 1 Nickel hydroxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂LiOH•H₂O 760 20 45 Example 2 Nickel oxyhydroxideLi_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 20 45 Example 3Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 20 45Example 4 Nickel oxideLi_(1.02)Ni_(0.804)Co_(0.148)Al_(0.036)Mg_(0.012)O₂ LiOH•H₂O 760 20 45Example 5 Nickel oxideLi_(1.02)Ni_(0.786)Co_(0.151)Al_(0.035)Mg_(0.028)O₂ LiOH•H₂O 760 20 45Example 6 Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ Li₂O 76020 45 Example 7 Nickel oxide Li_(1.02)Ni_(0.81)Co_(0.16)Al_(0.03)O₂LiOH•H₂O 700 20 45 Example 8 Nickel oxideLi_(1.02)Ni_(0.83)Co_(0.14)Al_(0.03)O₂ LiOH•H₂O 800 20 45 Example 9Nickel oxide Li_(1.02)Ni_(0.81)Co_(0.16)Al_(0.03)O₂ LiOH•H₂O 760 15 45Example 10 Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O760 30 45 Example 11 Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂LiOH•H₂O 760 35 45 Example 12 Nickel oxideLi_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 12 45 Example 13Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 38 45Example 14 Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O760 10 45 Example 15 Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂LiOH•H₂O 760 40 45 Comparative Nickel oxideLi_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 0 45 Example 1Comparative Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O760 50 45 Example 2 Comparative Nickel oxideLi_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O 760 20 70 Example 3Comparative Nickel oxide Li_(1.02)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ LiOH•H₂O760 20 20 Example 4

TABLE 2 Specific Initial Amount of Gas generation surface Resistancedischarge lithium on amount at high area Rct capacity TC surfacetemperature Chemical composition (m²/g) (a. u.) (mAhg) (% by mass) (% bymass) (index) Example 1 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 2.0 100187 0.02 0.03 5 Example 2 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 0.83 99187 0.02 0.03 5 Example 3 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.50 97186 0.02 0.03 5 Example 4Li_(0.912)Ni_(0.804)Co_(0.148)Al_(0.036)Mn_(0.012)O₂ 0.69 98 186 0.020.03 5 Example 5 Li_(0.91)Ni_(0.786)Co_(0.151)Al_(0.035)Mn_(0.028)O₂0.64 101 186 0.02 0.03 5 Example 6Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 0.52 99 188 0.02 0.03 5 Example 7Li_(0.91)Ni_(0.81)Co_(0.16)Al_(0.03)O₂ 1.50 130 177 0.06 0.08 5 Example8 Li_(0.91)Ni_(0.83)Co_(0.14)Al_(0.03)O₂ 0.69 120 176 0.06 0.07 5Example 9 Li_(0.91)Ni_(0.81)Co_(0.16)Al_(0.03)O₂ 1.12 98 188 0.03 0.04 7Example 10 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.29 103 185 0.020.035 6 Example 11 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.49 109 1850.03 0.04 7 Example 12 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.12 120182 0.05 0.06 8 Example 13 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.52115 182 0.05 0.06 8 Example 14 Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂1.11 134 180 0.07 0.09 10 Example 15Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.56 120 180 0.07 0.09 10Comparative Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 1.11 180 135 0.090.11 12 Example 1 Comparative Li_(0.91)Ni_(0.82)Co_(0.15)Al_(0.03)O₂1.67 150 160 0.09 0.11 12 Example 2 ComparativeLi_(1.00)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 0.98 160 175 0.09 0.13 14 Example3 Comparative Li_(0.84)Ni_(0.82)Co_(0.15)Al_(0.03)O₂ 2.10 175 130 0.030.03 5 Example 4

It follows from Tables 1 and 2 that in Examples 1 to 13, which satisfyall of the requirements of the present invention, the resultant positiveelectrode active materials have a low internal resistance, a highcapacity and a small amount of gas generation at a high temperature.

By contrast, in Comparatives Example 1, which does not satisfy some orall of the requirements of the present invention, since the waterwashing temperature is low, water washing is insufficient, the contentof carbon (TC) increases, and the internal resistance increasessignificantly. Further, in Comparative Example 2, since the waterwashing temperature is high, the elution of lithium during water washingincreases, the capacity decreases, and the internal resistanceincreases. Furthermore, in Comparative Example 3, since the liquidelectrical conductivity is high and water washing is not sufficient, thecontent of carbon increases, internal resistance increases, and theamount of gas generation at a high temperature increases. In ComparativeExample 4, since the liquid electrical conductivity is low andover-washing is performed, the elution of lithium during water washingincreases, the capacity decreases, and the internal resistanceincreases.

INDUSTRIAL APPLICABILITY

As is clear from the above, the positive electrode active material for anonaqueous electrolyte secondary battery in accordance with the presentinvention is constituted by a lithium nickel composite oxide with asmall internal resistance and excellent thermal stability, and anonaqueous electrolyte secondary battery of a high capacity and highsafety can be obtained by using such a positive electrode activematerial. Further, the nonaqueous electrolyte secondary battery usingthe positive electrode active material in accordance with the presentinvention is advantageous as a rechargeable secondary battery to be usedin the field of small electronic devices and has very high industrialapplicability.

REFERENCE SIGNS LIST

-   -   1 positive electrode (electrode for evaluation)    -   2 separator (impregnated with electrolytic solution)    -   3 metallic lithium negative electrode    -   4 gasket    -   5 positive electrode case    -   6 negative electrode case

What is claimed is:
 1. A method for manufacturing a positive electrodeactive material for a nonaqueous electrolyte secondary battery, themethod comprising: (a) a step for preparing a fired powder of a lithiumnickel composite oxide represented by the following composition formula(3):Composition formula: Li_(b)Ni_(1-a)M1_(a)O₂  (3) (where M1 represents atleast one element selected from transition metal elements other than Ni,elements of the second group of the Periodic System and elements of thethirteenth group of the Periodic System; a satisfies the condition0.01≤a≤0.5; and b satisfies the condition 0.95≤b≤1.13) by mixing atleast one nickel compound selected from a nickel hydroxide includingnickel as a main component and at least one element selected from othertransition metal elements, elements of the second group of the PeriodicSystem, and elements of the thirteenth group of the Periodic System asan auxiliary component, a nickel oxyhydroxide thereof, and a nickeloxide obtained by roasting thereof, and a lithium compound, and thenfiring the mixture at a maximum temperature in a range of 650° C. to850° C. under oxygen atmosphere; and (b) a step for preparing a lithiumnickel composite oxide powder by mixing the fired powder with water toobtain a slurry, washing the fired powder with water at a temperature of10° C. to 40° C., while controlling an electrical conductivity of aliquid portion of the slurry to 30 mS/cm to 60 mS/cm, then filtering anddrying the resultant fired powder.
 2. The method according to claim 1,wherein in the step (b), the fired powder after water washing treatmentis dried under a gas atmosphere including no compound componentcontaining carbon, or under a vacuum atmosphere.
 3. The method accordingto claim 1, wherein the nickel hydroxide is prepared by dropping anaqueous solution of a metal compound including nickel as a maincomponent and at least one element selected from other transition metalelements, elements of the second group of the Periodic System, andelements of the thirteenth group of the Periodic System as an auxiliarycomponent, and an aqueous solution including an ammonium ion supplyingsubstance into a heated reaction tank, and optionally dropping, asappropriate, in this process, an aqueous solution of an alkali metalhydroxide in an amount necessary to maintain a reaction solution in analkaline state.
 4. The method according to claim 1, wherein the nickeloxyhydroxide is prepared by dropping an aqueous solution of a metalcompound including nickel as a main component and at least one elementselected from other transition metal elements, elements of the secondgroup of the Periodic System, and elements of the thirteenth group ofthe Periodic System as an auxiliary component, and an aqueous solutionincluding an ammonium ion supplying substance into a heated reactiontank, optionally dropping, as appropriate, in this process, an aqueoussolution of an alkali metal hydroxide in an amount necessary to maintaina reaction solution in an alkaline state, and then adding an oxidizingagent.
 5. The method according to claim 1, wherein the lithium compoundis at least one selected from the group consisting of lithium hydroxide,oxyhydroxide, oxide, carbonate, nitrate, and halides.
 6. The methodaccording to claim 1, wherein in step (a), a mixing ratio of the nickelcompound and lithium compound is 0.95 to 1.13 as a molar ratio of alithium amount in the lithium compound to a total amount of nickel,other transition metal elements, elements of the second group of thePeriodic System, and elements of the thirteen group of the PeriodicSystem in the nickel oxide.
 7. The method according to claim 1, whereinthe manufactured positive electrode active material comprises a lithiumnickel composite oxide represented by the following general formula (1):General formula: Li_(b)Ni_(1-a)M1_(a)O₂  (1) (where M1 represents atleast one element selected from transition metal elements other than Ni,elements of the second group of the Periodic System and elements of thethirteenth group of the Periodic System; a satisfies the condition0.01≤a≤0.5; and b satisfies the condition 0.85≤b≤1.05), wherein aspecific surface area is 0.5 m²/g to 2.05 m²/g and a content of carbonin the lithium nickel composite oxide is a value equal to or less than0.08% by mass of a total mass of the lithium nickel composite oxide,wherein a total content of lithium present on a surface of the lithiumnickel composite oxide is a value equal to or less than 0.05% by mass ofa total mass of the lithium nickel composite oxide, the total content oflithium being determined based on lithium compounds present on thesurface of the lithium nickel composite oxide, the lithium compoundscomprising at least lithium hydroxide and lithium carbonate, wherein thetotal content of lithium present on the surface is a mass ratio oflithium to lithium nickel composite oxide as defined by adding thelithium nickel composite oxide to a solution to obtain a slurry,determining an amount of an alkali fraction by titrating a pH of theslurry with an acid, under an assumption that an amount of lithiumcompounds present on the surface corresponds to the amount of the totalalkali fraction in the slurry, and recalculating the amount of thelithium compounds into the total content of lithium present on thesurface, and wherein the lithium nickel composite oxide is representedby the following general formula (2):General formula: Li_(b)Ni_(1-x-y-z)Co_(x)Al_(y)M2_(x)O₂  (2) in which M2is at least one element selected from the group consisting of Mn, Ti,Ca, and Mg; b satisfies the condition 0.85≤b≤1.05; x satisfies thecondition 0.05≤x≤0.30; y satisfies the condition 0.01≤y≤0.1; and zsatisfies the condition 0≤z≤0.05.
 8. The method according to claim 7,wherein the content of carbon is 0.01% by mass to 0.04% by mass.
 9. Themethod according to claim 7, wherein the acid is at least one acidselected from the group consisting of hydrochloric acid, sulfuric acid,nitric acid, and organic acids.